Flame-retardant carpet made of nylon 6 pile, flame retardant, and method for manufacturing a flame-retardant carpet.

Abstract

By attaching sulfamic acid guazinine and other similar substances to guanidine salts of alkyl acid phosphate esters, we achieve "flame retardancy to nylon 6-pile carpets," etc. [Solution] A nylon 6-pile carpet 1 is coated with a flame retardant X, which has a first flame retardant X1, guazinine sulfamate, and a second flame retardant X2, which is a guanidine salt of an alkyl acid phosphate ester. The base fabric 3 is polypropylene, and the first flame retardant X1 may also contain ammonium sulfate, the ratio of the amounts of the first and second flame retardants X1 and X2 to be coated may be 132:3 to 132:14, and a penetrating agent Y such as acetylene glycol may also be coated. The flame retardant X has the first and second flame retardants X1 and X2, and the first flame retardant X1 may also contain ammonium sulfate, and the second flame retardant X2 may be a viscous substance at room temperature. The method for manufacturing the carpet 1 may involve applying the flame retardant X, the second flame retardant X2 may be a viscous substance at room temperature, or the flame retardant X may be spray-coated.

Description

[Technical Field]

[0001] This invention relates to a carpet (flame-retardant carpet) made of nylon 6 fibers with a pile and flame-retardant properties, a flame retardant, and a method for manufacturing a flame-retardant carpet. [Background technology]

[0002] Conventionally, flame-retardant tufted carpets are known (Patent Document 1). This flame-retardant tufted carpet comprises a base fabric layer having a polypropylene fabric, a pile layer formed by adding a flame retardant to 66 nylon long fiber yarns and planting them on the surface of the base fabric layer, a flame-retardant rayon cotton layer disposed between the base fabric layer and the pile layer, and a backing resin layer containing a flame-retardant resin disposed on the back surface of the base fabric layer. [Prior art documents] [Patent Documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2020-121016 [Overview of the project] [Problems that the invention aims to solve]

[0004] In the flame-retardant tufted carpet described in Patent Document 1, long-fiber yarn of nylon 66 (also called "nylon 66") is used in the pile layer, but in some cases, nylon 6, which has a lower unit price, is used to form the pile. Comparing nylon 6 and nylon 66, as shown in the structural formulas (1) and (2) below, the number of "CH2" groups, which are easily to which flame-retardant substances can be attached, is 10 in the structural formula (1) of nylon 66, but only 5 in the structural formula (2) of nylon 6. Therefore, carpets with piles formed from nylon 6 resin fibers (also called "nylon 6 piles") are less likely to be given flame retardancy.

[0005] [ka]

[0006] [ka]

[0007] Furthermore, the difference in these structural formulas can be attributed to the difference in melting points; nylon 66 has a high melting point of 265°C, while nylon 6 has a lower melting point of 225°C. This also makes it difficult to impart flame retardancy to carpets with nylon 6 pile.

[0008] In view of these points, the present invention aims to provide a carpet, a flame retardant, and a method for manufacturing a carpet that achieves "flame retardancy to a nylon 6 pile carpet" by, for example, attaching a first flame retardant, guazinine sulfamate, and a second flame retardant, guanidine salt of an alkyl acid phosphate ester, to a carpet having a nylon 6 pile. [Means for solving the problem]

[0009] The carpet 1 according to the present invention is a carpet in which piles 2 are provided on a base fabric 3, wherein the piles 2 are made of nylon 6 fibers, and at least the piles 2 are coated with a flame retardant X having a first flame retardant X1 and a second flame retardant X2, wherein the first flame retardant X1 contains sulfamic acid guazinine, and the second flame retardant X2 contains a guanidine salt of an alkyl acid phosphate ester.

[0010] A second feature of the carpet 1 according to the present invention is that, in addition to the first feature described above, the base fabric 3 is made of polypropylene fibers, the first flame retardant X1 includes ammonium sulfate, or a mixture of ammonium sulfate and phosphorus-nitrogen-based onium salt, and the flame retardant X is attached to the pile 2 and the base fabric 3.

[0011] A third feature of the carpet 1 according to the present invention is that, in addition to the first or second feature described above, the ratio of the amount of the first flame retardant X1 to the amount of the second flame retardant X2 is 132:3 to 132:14. Note that the numerical range "132:3 to 132:14" in this invention includes the boundary values ​​of "132:3" and "132:14".

[0012] A fourth feature of the carpet 1 according to the present invention is that, in addition to the first feature described above, a penetrating agent Y is also attached to at least the pile 2, and the penetrating agent Y contains an acetylene glycol-based penetrating agent.

[0013] The flame retardant X according to the present invention is a flame retardant comprising a first flame retardant X1 and a second flame retardant X2, wherein the first flame retardant X1 contains sulfamic acid guazinine, and the second flame retardant X2 contains a guanidine salt of an alkyl acid phosphate ester.

[0014] A second feature of the flame retardant X according to the present invention is that, in addition to the first feature described above, the first flame retardant X1 also contains ammonium sulfate, or a mixture of ammonium sulfate and a phosphorus-nitrogen-based onium salt.

[0015] A third feature of the flame retardant X according to the present invention is that, in addition to the first or second feature described above, the second flame retardant X2 is a viscous substance at room temperature.

[0016] The first characteristic of the method for manufacturing a carpet 1 according to the present invention is a method for manufacturing a carpet in which pile 2 is provided on a base fabric 3, wherein nylon 6 fibers are used for the pile 2, and at least the pile 2 is provided with a flame retardant X having a first flame retardant X1 and a second flame retardant X2, wherein the first flame retardant X1 contains sulfamic acid guazinine, and the second flame retardant X2 contains a guanidine salt of an alkyl acid phosphate ester.

[0017] A second feature of the method for manufacturing the carpet 1 according to the present invention is that, in addition to the first feature described above, the second flame retardant X2 is a viscous substance at room temperature.

[0018] A third feature of the method for manufacturing the carpet 1 according to the present invention is that, in addition to the first or second feature described above, the flame retardant X is applied to at least the pile 2 by spray coating.

[0019] Due to these characteristics, when a flame retardant X containing sulfamic acid guanidine as the first flame retardant X1 and an alkyl acid phosphate guanidine salt as the second flame retardant X2 is applied to a nylon 6 pile carpet 1, unlike in Patent Document 1, because it contains not only sulfamic acid guanidine, which is normally solid, but also an alkyl acid phosphate guanidine salt, which is normally liquid, the flame retardant X becomes viscous and adheres firmly to the nylon 6 pile 2, which has a low melting point and a small number of "CH2" groups, making it easier to impart flame retardancy. Furthermore, since Carpet 1 is a carpet with a pile made of nylon 6 fibers and is treated with flame retardancy, it can also be described as a "flame-retardant carpet with nylon 6 pile," and the manufacturing method of Carpet 1 can also be described as a "method for manufacturing a flame-retardant carpet."

[0020] Furthermore, if polypropylene fibers, which have a low melting point and are easily flammable, are used as the base fabric 3 in a nylon 6 pile carpet 1, even if the combustion of the nylon 6 pile 2 is suppressed, a two-stage combustion may occur, such as the polypropylene fiber base fabric 3 starting to burn afterward. In this case as well, by further including ammonium sulfate or a mixture of ammonium sulfate and phosphorus-nitrogen-based onium salt as the first flame retardant X1, the combustion of the polypropylene fiber base fabric 3 can be suppressed, and as a result, flame retardancy can be imparted to the entire nylon 6 pile carpet 1.

[0021] Furthermore, if the amount of the first flame retardant X1, such as sulfamic acid guazinine, which is normally a solid, becomes too large, the carpet 1 will whiten (a white powder will be released). On the other hand, if the amount of the second flame retardant X2, such as the guanidine salt of alkyl acid phosphate ester, which is normally a liquid, becomes too large, tackiness (stickiness) may occur on the pile surface. Even in this case, by setting the ratio of the amount of the first flame retardant X1 to the second flame retardant X2 to 132:3 to 132:14, it is possible to achieve both "whitening suppression" and "tack reduction" in the carpet 1.

[0022] Furthermore, by applying acetylene glycol-based penetrating agent Y to the nylon 6-pile carpet 1, the flame retardant X adheres more firmly not only to the tip of the pile 2 but also to the base fabric 3 of the pile 2. As a result, flame retardancy can be imparted to the nylon 6-pile carpet 1 without applying a large amount of flame retardant X, and "whitening suppression" and other effects can be achieved.

[0023] On the other hand, in the flame retardant X, by having a first flame retardant X1 containing sulfamic acid guazinine and a second flame retardant X2 containing an alkyl acid phosphate guanidine salt, the flame retardant X becomes viscous, allowing it to adhere firmly to the nylon 6 pile 2 and easily impart flame retardancy. Furthermore, in the flame retardant X, if the first flame retardant X1 also contains ammonium sulfate or a mixture of ammonium sulfate and phosphorus-nitrogen-based onium salt, even if polypropylene fibers are used for the base fabric 3 and combustion occurs in two stages, such as when the combustion of the nylon 6 pile 2 is suppressed and then the polypropylene fiber base fabric 3 starts to burn, the combustion of the polypropylene fiber base fabric 3 can be suppressed, and flame retardancy can be imparted to the entire nylon 6 pile carpet 1. Furthermore, in the flame retardant X, the second flame retardant X2, including the guanidine salt of the alkyl acid phosphate ester, is a viscous substance (also called a viscous liquid) at room temperature as a whole. This makes the entire flame retardant X viscous, which facilitates the imparting of flame retardancy to carpets 1 such as nylon 6 pile. This is also true in the manufacturing method of nylon 6 pile carpet 1, even when the second flame retardant X2 is a viscous substance at room temperature. Furthermore, in the manufacturing method of a nylon 6-pile carpet 1, if the carpet 1 exceeds a predetermined size, it may not fit into the impregnation tank, making it impossible to impregnate it and apply the flame retardant X. Even in this case, by spray-applying the flame retardant X to the carpet 1, it becomes possible to apply the flame retardant X regardless of the size of the carpet 1. [Effects of the Invention]

[0024] According to the carpet, flame retardant, and carpet manufacturing method of the present invention, by applying a first flame retardant, guazinine sulfamate, and a second flame retardant, guanidine salt of an alkyl acid phosphate ester, to a carpet having a pile of nylon 6 fibers, it is possible to "impart flame retardancy to the nylon 6 pile carpet." [Brief explanation of the drawing]

[0025] [Figure 1] This is a schematic diagram showing the carpet and flame retardant according to the present invention. [Figure 2] This is a schematic diagram showing the adhesion of elements such as sulfur (S) among the flame retardants in the carpet of Example 1', where (a) shows the tip of the pile, (b) shows the middle part of the pile, and (c) shows the base end of the pile and the base fabric. In Figure 2, the white dots (whitish dots) represent sulfur, etc. [Figure 3] A flowchart illustrating a method for manufacturing a carpet according to the present invention, where (a) shows a first embodiment and (b) shows a second embodiment. [Modes for carrying out the invention]

[0026] <Overall composition of Carpet 1> Hereinafter, embodiments of the present invention will be described with reference to the drawings. Figures 1 and 2 show a carpet 1 according to the present invention, which has a pile 2 and a base fabric 3, which will be described later. Carpet 1 has flame retardant X attached to at least the pile 2. Carpet 1 may have the penetrating agent Y described later attached to it (applied to it), and may also have a back coat portion 10 described later. In this invention, the "surface (fabric surface) 1a" of the carpet 1 can also be said to be the side that is exposed when used as interior material for railway vehicles, seat covers for seats, etc. Conversely, the "back surface (fabric back surface) 1b" of the carpet 1 in this invention can also be said to be the side that is not exposed when used as interior material, seat, etc. for railway vehicles, etc.

[0027] Carpet 1 can be any of the following: for example, it may be a pile fabric having warp and weft threads, a pile knitted fabric having only warp threads or only weft threads, or a tufted carpet in which pile 2 is planted (tufted) on a base fabric 3. In particular, if carpet 1 is a pile fabric, any configuration is acceptable, but for example, a base fabric 3 may be made by weaving the warp and weft threads in a plain weave, twill weave, satin weave, etc., and the pile 2 may be constructed by weaving pile threads together with this base fabric 3 in the warp or weft direction. Furthermore, pile fabrics in which the pile threads are woven in the warp direction are also called warp pile fabrics, and pile fabrics in which the pile threads are woven in the weft direction are also called weft pile fabrics. Even if carpet 1 is a pile knit, any configuration is acceptable, but for example, it may be a pile knit with weft yarn (a type of weft knit that is a variation of plain knit, also called pile standing knit or plush knit), in which pile yarn is knitted in addition to the ground yarn weft, and the sinker loop of this pile yarn is enlarged to form pile 2, and the plain knit fabric knitted with the ground yarn weft becomes the base fabric 3.

[0028] The thickness of the carpet 1 is not particularly limited, and for example, it may be 1 mm or more and 100 mm or less. More specifically, the lower limit value may be 1 mm or more, preferably 3 mm or more, and more preferably 5 mm or more, and the upper limit value may be 100 mm or less, preferably 70 mm or less, and more preferably 40 mm or less. In addition, any of the lower limit values of this thickness may be combined with any of the upper limit values. In addition, the density of the yarn used for the carpet 1 is not particularly limited. However, when the carpet 1 is the above-mentioned warp pile fabric, the density of the pile yarn (pile 2) woven in the warp direction in the carpet 1 may be, for example, 50 yarns / 10 cm or more and 260 yarns / 10 cm or less. More specifically, the lower limit value may be 50 yarns / 10 cm or more, preferably 60 yarns / 10 cm or more, and more preferably 70 yarns / 10 cm or more, and the upper limit value may be 260 yarns / 10 cm or less, preferably 240 yarns / 10 cm or less, and more preferably 220 yarns / 10 cm or less. In addition, any of the lower limit values of this density may be combined with any of the upper limit values. Also, when the carpet 1 is a pile fabric, the density of the weft yarn forming the base fabric 3 may be, for example, 100 yarns / 10 cm or more and 260 yarns / 10 cm or less. More specifically, the lower limit value may be 100 yarns / 10 cm or more, preferably 120 yarns / 10 cm or more, and more preferably 140 yarns / 10 cm or more, and the upper limit value may be 260 yarns / 10 cm or less, preferably 240 yarns / 10 cm or less, and more preferably 220 yarns / 10 cm or less. In addition, any of the lower limit values of this density may be combined with any of the upper limit values. The basis weight of the carpet 1 is not particularly limited, and for example, it may be 300 g / m 2 or more and 3000 g / m 2 or less. More specifically, the lower limit value may be 300 g / m 2 or more, preferably 450 g / m 2 or more, and more preferably 600 g / m 2 or more, and the upper limit value may be 3000 g / m 2 or less, preferably 2000 g / m 2 or less, and more preferably 1500 g / m 2 or less (1018 g / m 2It may also be (etc.). Furthermore, each of these lower limits of basis weight may be combined with any of the upper limits. Also, the basis weight, adhesion amount, and application amount (g / m) in this invention may be specified. 2 ) usually refers to the value based on dry weight. Hereafter, carpet 1 will be described primarily as a pile fabric (mocket) 1.

[0029] <Pile 2> As shown in Figures 1 and 2, the pile 2 is provided on the base fabric 3, which will be described later, and the pile 2 may also be erected from the base fabric 3. Pile 2 is made of nylon 6 fibers and has the flame retardant X, which will be described later, attached to it. Here, nylon 6 fiber (nylon 6 resin fiber) is represented by the following structural formula (1).

[0030] [ka]

[0031] This nylon 6 resin is a polymer that has amide bonds in the repeating units of its main chain (more specifically, it has "-C(=O)NH-" bonds, which consist of a bond between the -C(=O)- portion of one adjacent repeating unit and the -NH- portion of the other). It is synthesized by ring-opening polymerization of caprolactam, which is obtained by condensing and cyclizing the raw material carboxylic acid amine, and is also called a polyamide resin. Because nylon 6 resin uses carboxylic acid amine as a raw material, it is called n-type. In the repeating unit, there are six carbon atoms in total: one carbon atom in the -C(=O)- portion and five carbon atoms in the -(CH2)5- portion between the -C(=O)- portion and the -NH- portion. Therefore, it is a type 6 polyamide resin (nylon resin), hence the name nylon 6 resin. On the other hand, nylon 66 is represented by the following structural formula (2).

[0032] [ka]

[0033] This nylon 66 resin is also a polymer that has amide bonds in the repeating units of its main chain (more precisely, it has a "-C(=O)NH-" in the center of the repeating unit and a "-C(=O)NH-" formed by the bond between one -C(=O)- portion and the other -NH- portion of an adjacent repeating unit). It is synthesized by condensation polymerization of the raw materials dicarboxylic acid and diamine, and is also called a polyamide resin. Because nylon 66 resin uses dicarboxylic acid and diamine as raw materials, it is called an m,n type. In the repeating unit, there are 6 carbon atoms in the -(CH2)6- portion between the two -NH- portions, and 6 carbon atoms in the two -C(=O)- portions and the -(CH2)4- portion between them, so it has 6 and 6 carbon atoms. Therefore, it is a 6,6 type nylon resin (polyamide resin), hence the name nylon 66 resin.

[0034] Furthermore, in this invention, "Pile 2 uses nylon 6 fibers" means that at least nylon (polyamide) 6 fibers are used in Pile 2. Not only may only nylon 6 fibers be used, but other fibers may also be used in conjunction with nylon 6 fibers. Here, fibers other than nylon 6 fibers may include, for example, thermoplastic fibers such as polyethylene terephthalate (PET) fibers, or other fibers having ester bonds such as polytrimethylene terephthalate (PTT) fibers and polybutylene terephthalate (PBT) fibers, or other polyolefin fibers such as polyethylene (PE) fibers and polypropylene (PP) fibers, or synthetic fibers such as rayon fibers, cupro fibers, acetate fibers, acrylic fibers mainly composed of polyacrylonitrile (PAN), polyvinyl alcohol (PVA) fibers (vinylon fibers), and polyurethane (PU) fibers. Other examples include glass fibers, wool, and silk, and these may be used individually or in combination. The following description assumes that Pile 2 primarily uses only nylon 6 fibers.

[0035] The yarn used for Pile 2 can be multifilament yarn, monofilament yarn, or spun yarn. Furthermore, there are no particular limitations on the fineness of the fibers constituting pile 2, but for example, the total fineness may be 20 dtex or more and 3000 dtex or less. More specifically, the lower limit may be 20 dtex or more, preferably 50 dtex or more, and even more preferably 100 dtex or more, or the upper limit may be 3000 dtex or less, preferably 2000 dtex or less, and even more preferably 1000 dtex or less. In the case of multifilament fibers constituting pile 2, there are no particular limitations on the single fiber fineness of each filament, but for example, it may be 0.1 dtex or more and 50.0 dtex or less. More specifically, the lower limit may be 0.1 dtex or more, preferably 0.5 dtex or more, and even more preferably 1.0 dtex or more, or the upper limit may be 50.0 dtex or less, preferably 30.0 dtex or less, and even more preferably 15.0 dtex or less. Furthermore, these lower limits for total fineness and single fiber fineness can be combined with any of the upper limits. Pile 2 can be either a cut pile, which has its tip cut to create a fuzzy surface, or a loop pile, which is formed by adjacent piles 2 forming loops together. The following discussion assumes that Pile 2 is primarily a cut pile.

[0036] The pile length of Pile 2 is not particularly limited, but for example, it may be between 0.5 mm and 10.0 mm. More specifically, the lower limit may be 0.5 mm or more, preferably 1.0 mm or more, and even more preferably 2.0 mm or more, and the upper limit may be 10.0 mm or less, preferably 8.0 mm or less, and even more preferably 6.0 mm or less. Furthermore, each of these lower limits of pile length may be combined with any of the upper limits. Pile height refers to the height from the surface of the base fabric 3 of the carpet 1 to the tip of the pile 2. More specifically, if the pile 2 is erected at approximately a right angle (approximately 90°) to the base fabric 3 (the angle θ between the pile 2 and the base fabric 3 is approximately 90°), then it can be said that the pile height is approximately equal to the pile length of the pile 2. Furthermore, if the pile 2 is erected at an angle to the base fabric 3 (i.e., the angle θ between the pile 2 and the base fabric 3 is less than 90° (for example, 80°, 70°, 60°, 45°, etc.)), the pile height will be approximately equal to the pile length × sinθ. There are no particular limitations on the pile height, but for example, it may be between 0.5 mm and 10.0 mm. More specifically, the lower limit may be 0.5 mm or more, preferably 1.0 mm or more, and even more preferably 2.0 mm or more, while the upper limit may be 10.0 mm or less, preferably 8.0 mm or less, and even more preferably 6.0 mm or less. Furthermore, each of these lower limits of pile height may be combined with any of the upper limits. There are no particular restrictions on the pile weight of Pile 2, but for example, 200g / m 2 More than 2500g / m 2 The following is also acceptable, and to elaborate further, the lower limit is 200g / m 2 Preferably 350 g / m² 2 More preferably 500 g / m² 2 If it is above that, or if the upper limit is 2500g / m² 2 Preferably 2000 g / m² 2 More preferably, 1500 g / m 2 Below (907g / m 2 (etc.) are also acceptable. Furthermore, each of these lower limits may be combined with any of the upper limits.

[0037] <Base fabric 3> As shown in Figures 1 and 2, the base fabric 3 is provided with the pile 2 described above, and the pile 2 may be erected from the base fabric 3. The base fabric 3 may be made of polypropylene (PP) fibers and may have the flame retardant X described later attached to it. Furthermore, in this invention, "the base fabric 3 uses polypropylene fibers" means that at least polypropylene (PP) fibers are used in the base fabric 3. This does not mean that only polypropylene fibers are used, but that other fibers may be used in conjunction with polypropylene fibers. Here, fibers other than polypropylene fibers may include, for example, thermoplastic fibers such as polyethylene terephthalate (PET) fibers, or other fibers having ester bonds such as polytrimethylene terephthalate (PTT) fibers and polybutylene terephthalate (PBT) fibers, or other nylon (polyamide) fibers such as nylon 6 fibers, nylon 66 fibers, nylon 11 fibers, and nylon 12 fibers, or polyolefin fibers such as polyethylene (PE) other than polypropylene (PP) fibers, or synthetic fibers such as rayon fibers, cupro fibers, acetate fibers, acrylic fibers mainly composed of polyacrylonitrile (PAN), polyvinyl alcohol (PVA) fibers (vinylon fibers), and polyurethane (PU) fibers. Other examples include glass fibers, wool, and silk, and these may be used individually or in combination. The following description assumes that base fabric 3 primarily uses only polypropylene fibers.

[0038] The yarn of this base fabric 3 may be multifilament yarn, monofilament yarn, or spun yarn. Furthermore, the fineness of the fibers constituting the base fabric 3 may be any value, but for example, the total fineness may be 20 dtex or more and 3000 dtex or less. More specifically, the lower limit may be 20 dtex or more, preferably 50 dtex or more, and even more preferably 100 dtex or more, and the upper limit may be 3000 dtex or less, preferably 2000 dtex or less, and even more preferably 1000 dtex or less. In the case of multifilament fibers constituting the base fabric 3, there are no particular limitations on the single fiber fineness of each filament, but for example, it may be 0.1 dtex or more and 50.0 dtex or less. More specifically, the lower limit may be 0.1 dtex or more, preferably 0.5 dtex or more, and even more preferably 1.0 dtex or more, and the upper limit may be 50.0 dtex or less, preferably 30.0 dtex or less, and even more preferably 15.0 dtex or less. Furthermore, these lower limits for total fineness and single fiber fineness can be combined with any of the upper limits.

[0039] As described above, the base fabric 3 is a woven or knitted fabric composed of warp and weft threads, and is in the form of a sheet. Here, the "surface (base fabric surface) 3a" of the base fabric 3 in this invention can also be said to be the surface close to the surface 1a that is exposed when the carpet 1 is used to cover the interior of a railway vehicle, and the pile 2 is provided on this surface 3a side. Conversely, the "back surface (back surface of the base fabric) 3b" of the base fabric 3 in this invention can also be said to be the surface close to the back surface 1b that is not exposed when the carpet 1 is used to cover interior parts of railway vehicles, etc. (if the carpet 1 does not have a back coat portion 10, then, so to speak, the back surface 1b of the carpet 1 itself). The thickness of the base fabric 3 is not particularly limited, but for example, it may be 0.1 mm or more and 2.0 mm or less. More specifically, the lower limit may be 0.1 mm or more, preferably 0.2 mm or more, and even more preferably 0.5 mm or more, and the upper limit may be 2.0 mm or less, preferably 1.5 mm or less, and even more preferably 2.0 mm or less. Furthermore, each of these lower limits of thickness may be combined with any of the upper limits. There are no particular restrictions on the weight of the base fabric 3, but for example, 50g / m 2 More than 500g / m 2 The following is also acceptable, and to elaborate further, the lower limit is 50g / m 2 Preferably 60 g / m² 2 More preferably 70 g / m² 2 If it is above that, or if the upper limit is 500g / m 2 Preferably 200 g / m 2 More preferably, 140 g / m² 2 Below (111g / m 2 (etc.) are also acceptable. Furthermore, each of these lower limits may be combined with any of the upper limits.

[0040] <Flame retardant X> As shown in Figures 1 and 2, the flame retardant X is at least attached to the pile 2 described above, and may also be attached to the base fabric 3 described above. Flame retardant X has (includes) a first flame retardant X1, described later, and a second flame retardant X2, described later. Furthermore, the flame retardant X may be in a glue-like state overall. Here, "glue-like" in this invention means being in a glue-like state (regardless of the substance contained in the functional agent K), or being in a highly viscous liquid state, and can also be described as gelatinous, jelly-like, gel-like, or jelly-like. In addition, the entire flame retardant X may be in the form of a dispersion liquid mixed with the penetrating agent Y, etc., described later, and dispersed in a dispersion medium such as water, or it may be in the form of a dispersion liquid in which only the flame retardant X is dispersed in a dispersion medium without being mixed with the penetrating agent Y, etc.

[0041] There are no particular limitations on the total amount of flame retardant X that is applied (also called the amount applied or coated), but for example, 1.00 g / m² by dry weight. 2 More than 300.00g / m 2 The following is also acceptable, and to elaborate further, the lower limit is 1.00 g / m³. 2 Preferably 20.00 g / m² 2 More preferably 40.00 g / m 2 If it is above that, or if the upper limit is 300.00 g / m³ 2 Preferably, 200.00 g / m 2 More preferably, 100.00 g / m 2 Below (40.00g / m 2 or 52.80 g / m 2 66.00 g / m 2 67.32 g / m² 2 67.95g / m 2 69.30 g / m² 2 71.28 g / m² 2 72.60 g / m 2 75.90 g / m 2 89.10 g / m 2 132.00 g / m 2 (etc.) are also acceptable. Furthermore, each lower limit of the dry weight adhesion amount may be combined with any of the upper limits. Such flame retardant X may be scattered, present in an island-like pattern on the surface of the fibers used in the pile 2 or base fabric 3 of the carpet 1, or in a substantially planar area of ​​a predetermined size, when viewed in the direction normal to the fiber surface.

[0042] <First flame retardant X1> The first flame retardant X1 is a part of the flame retardant X described above and contains at least guazinine sulfamate (CH5N3·HSO3NH2). The first flame retardant X1 may also contain ammonium sulfate, or a mixture of ammonium sulfate and a phosphorus-nitrogen-based (such as calcium-based) onium salt. In other words, the first flame retardant X1 contains at least guazinine sulfamate, and may further contain ammonium sulfate, or a mixture of ammonium sulfate and a phosphorus-nitrogen-based onium salt. Furthermore, the first flame retardant X1 may consist only of guazinine sulfamate, or of guazinine sulfamate and ammonium sulfate, or of a mixture of guazinine sulfamate, ammonium sulfate, and a phosphorus-nitrogen-based onium salt. The first flame retardant X1 may be solid as a whole at room temperature (20°C, 25°C, or between 20°C and 25°C, etc.). When the first flame retardant X1 is solid at room temperature, at least guazinine sulfamate is solid at room temperature (specifically, in the form of a white lump, etc.), and if it contains ammonium sulfate or a mixture of ammonium sulfate and phosphorus-nitrogen-based onium salts, the ammonium sulfate, etc. may also be solid at room temperature (specifically, in the form of orthorhombic crystals or granular crystals, etc.). Furthermore, the first flame retardant X1 can also be said to be solid at the aforementioned room temperature and atmospheric pressure (normal atmospheric pressure, such as 1 atmosphere (1 atm)).

[0043] If the first flame retardant X1 is solid at room temperature, it may be crushed into particles, and these particles may be approximately spherical, lumpy, polyhedral, plate-like, needle-like, or the like. If the first flame retardant X1 is solid at room temperature and in particle form, and the particle shape is approximately spherical, there are no particular limitations on its average particle diameter, but for example, it may be between 0.10 μm and 1.60 μm. More specifically, the lower limit may be 0.10 μm or more, preferably 0.20 μm or more, and even more preferably 0.30 μm or more, and the upper limit may be 1.60 μm or less, preferably 1.20 μm or less, and even more preferably 0.80 μm or less. Note that each of these lower limits of the average particle diameter may be combined with any of the upper limits. If the first flame retardant X1 is solid at room temperature and in particulate form, the first flame retardant X1 may be applied to the pile 2 or base fabric 3 in the form of a solution dissolved in water or an organic solvent. The amount of the first flame retardant X1 applied (also called the amount applied or coated) is not particularly limited, but for example, 5.00 g / m² by dry weight. 2 More than 300.00g / m 2 The following is also acceptable, and to elaborate further, the lower limit is 5.00 g / m³. 2 Preferably 10.00 g / m 2 More preferably 20.00 g / m 2 If it is above that, or if the upper limit is 300.00 g / m³ 2 Preferably, 200.00 g / m 2 More preferably, 100.00 g / m 2 Below (40.00g / m 2 or 52.80 g / m 2 66.00 g / m 2 82.50 g / m 2 132.00 g / m 2 (etc.) are also acceptable. Furthermore, each lower limit of the dry weight adhesion amount may be combined with any of the upper limits. When such a first flame retardant X1 is applied to the pile 2 or base fabric 3 and adheres to the surface of the fibers used in the pile 2 or base fabric 3, if the first flame retardant X1 is solid at room temperature (and atmospheric pressure) and in particulate form, it can be said that it will adhere to the fiber surface directly or via the second flame retardant X2 described later, in its particulate form (see Figure 1).

[0044] <Second flame retardant X2> The second flame retardant X2 is a part of the flame retardant X described above and includes at least a guanidine salt of an alkyl acid phosphate ester. The second flame retardant X2 may consist solely of a guanidine salt of an alkyl acid phosphate ester. The second flame retardant X2 may be a liquid overall at room temperature (20°C, 25°C, or between 20°C and 25°C, etc.), and may also be a viscous substance (also called a viscous liquid) at room temperature. Furthermore, the second flame retardant X2 can also be described as a liquid (especially a viscous substance) at the aforementioned room temperature and atmospheric pressure (normal atmospheric pressure, such as 1 atmosphere (1 atm)). If the second flame retardant X2 is liquid at room temperature, the second flame retardant X2 may be mixed with a solution obtained by dissolving the first flame retardant X1, which is solid at room temperature and in particulate form, in a solvent, and then applied to the pile 2 or base fabric 3 as described above. There are no particular limitations on the amount of the second flame retardant X2 applied (also called the amount applied or coated), but for example, 0.10 g / m² by dry weight. 2 More than 30.00g / m 2 The following is also acceptable, and to elaborate further, the lower limit is 0.10 g / m³. 2 Preferably 1.00 g / m 2 More preferably 1.50 g / m 2 If the value is above that, or if the upper limit is 30.00 g / m³ 2 Preferably 20.00 g / m 2 More preferably, 10.00 g / m 2 Below (1.38g / m 2 or 1.98g / m 2 3.30 g / m 2 5.28 g / m 2 6.60 g / m 29.90g / m 2 (etc.) are also acceptable. Furthermore, each lower limit of the dry weight adhesion amount may be combined with any of the upper limits. When such a second flame retardant X2 is applied to the pile 2 or base fabric 3 and adheres to the surface of the fibers used in the pile 2 or base fabric 3, if the second flame retardant X2 is a liquid (especially a viscous material) at room temperature (and atmospheric pressure), it can be said that it will adhere to the fiber surface in a roughly layered manner when viewed in a side cross-section, and in an island-like manner in the direction normal to the fiber surface, or in a roughly planar manner of a predetermined size (see Figure 1).

[0045] <Ratio of the amount of flame retardants X1 and X2 applied> The ratio of the amount of the first flame retardant X1 and the second flame retardant X2 to be applied (or the amount applied or coated) is not particularly limited, but for example, it may be 132:3 to 132:14 (in other words, 132 / 14 (≒9.429) or more and 132 / 3 (=44.000) or less), and to elaborate further, the lower limit may be 132 / 14 or more, preferably 10.000 (=132 / 13.2) or more, even more preferably 11.000 (=132 / 12) or more, and the upper limit may be 132 / 3 (=44.000) or less, preferably 40.000 (=132 / 3.3) or less, even more preferably 30.000 (=132 / 4.4) or less (12.500, etc.). Furthermore, the lower and upper limits of the ratio of the amounts of flame retardants X1 and X2 applied may be combined with any of the upper limits.

[0046] <Other flame retardants> Flame retardant X may include specific flame retardants such as guazinine sulfamate, ammonium sulfate, a mixture of ammonium sulfate and phosphorus-nitrogen-based onium salts, or flame retardants other than guanidine salts of alkyl acid phosphate esters. For example, flame retardant X may include alkyl metal phosphate salts such as aluminum trisdiethylphosphinate, aluminum trismethylethylphosphinate, or aluminum trisdiphenylphosphinate. In addition, flame retardant X may contain phosphorus-based flame retardants such as ammonium polyphosphate, phosphate esters, and tris(1-chloro-2-propyl) phosphate, or metal hydroxide-based flame retardants such as aluminum hydroxide and magnesium hydroxide, non-halogen-based flame retardants, or silicone resins. These flame retardants may be solid at room temperature (or atmospheric pressure), in which case they may be included in the first flame retardant X1. Furthermore, these flame retardants may be liquid or viscous at room temperature (or atmospheric pressure), in which case they may be included in the second flame retardant X2.

[0047] <Penetrating agent Y> As shown in Figures 1 and 2, the penetrating agent Y is at least attached to the pile 2 described above, and may also be attached to the base fabric 3 described above. Penetrant Y contains at least an acetylene glycol-based penetrant. Here, the "acetylene glycol-based penetrating agent" in the present invention may be acetylene glycol alone, or it may be acetylene glycol derivative alone, or acetylene glycol and acetylene glycol derivative. Furthermore, acetylene glycol can also be described as a nonionic surfactant. Acetylene glycol derivatives can be described as acetylene glycol EO adducts, which are obtained by adding 10-80% ethylene oxide (EO) to acetylene glycol. Penetrating agent Y may also contain nonionic surfactants such as polyoxyalkylene alkyl ethers, in addition to the acetylene glycol-based penetrating agent mentioned above. Furthermore, it can be said that the penetrating agent Y is a liquid at room temperature and atmospheric pressure (normal atmospheric pressure, such as 1 atmosphere (1 atm)). There are no particular limitations on the amount of penetrating agent Y that adheres (also called the amount applied or coated), but for example, 0.01 g / m² by dry weight. 2 More than 5.00g / m 2 The following is also acceptable, and to elaborate further, the lower limit is 0.01 g / m³. 2 Preferably 0.05 g / m 2More preferably 0.10 g / m 2 If it is above that, or if the upper limit is 5.00 g / m 2 Preferably, 2.00 g / m 2 More preferably, 1.00 g / m 2 Below (0.40g / m 2 or 0.50g / m 2 (etc.) are also acceptable. Furthermore, each of these lower limits for adhesion amounts may be combined with any of the upper limits. The penetrating agent Y described above can be said to reduce the contact angle between the back surface of the pile 2 fibers and the flame retardant X, thereby promoting wetting and penetration in the flame retardant imparting process P1 and other processes described later (see Figure 2, etc.). When such a penetrating agent Y is applied to the pile 2 or base fabric 3 and adheres to the surface of the fibers used in the pile 2 or base fabric 3, if the penetrating agent Y is a liquid at room temperature (and atmospheric pressure), it can be said that it will adhere to the fiber surface in a roughly layered manner when viewed in a side cross-section, and in an island-like manner in the direction normal to the fiber surface, or in a roughly planar manner of a predetermined size (see Figure 1).

[0048] <Backcoat section 10> As shown in Figures 1 and 2, the back coat portion 10 is the portion on the back surface 3b of the base fabric 3 described above to which a backing material (backing agent) has been applied (back coat), and may be in the form of a layer of a predetermined thickness. The backing material of the back coat section 10 is not particularly limited, but may include synthetic rubbers such as styrene-butadiene rubber (SBR) or butadiene rubber (BR), or natural rubber (NR), or it may also contain urethane resins or vinyl chloride resins, and may also contain fillers (for example, calcium carbonate (CaCO3), also called fillers). In addition, the backing material may contain thickeners (for example, resins such as acrylic acid or hydroxyethylcellulose (HEC)), ammonia, or crosslinking agents. Furthermore, if the backing material is a mixture of multiple materials, it is also called a compound. Also, the backing material may be applied in a latex state.

[0049] Here, the "surface (back coat surface) 10a" of the back coat portion 10 in the present invention can also be said to be a surface close to the surface 1a that is exposed when the carpet 1 is used to cover interior parts of a railway vehicle or the like. It can also be said that the base fabric 3 is provided on the surface 10a side. Conversely, the "back surface (back coat back surface) 10b" of the back coat portion 10 in the present invention can also be said to be a surface close to the back surface 1b that is not exposed when the carpet 1 is used to cover interior parts of a railway vehicle or the like (if the carpet 1 has the back coat portion 10, it can be said to be the back surface 1b of the carpet 1 itself). The adhesion amount of the entire backing material in the back coat portion 10 is not particularly limited. For example, in terms of dry weight, it can be 300 g / m 2 or more and 3000 g / m 2 or less. More specifically, the lower limit value can be 300 g / m 2 or more, preferably 600 g / m 2 or more, more preferably 900 g / m 2 or more, and the upper limit value can be 3000 g / m 2 or less, preferably 2000 g / m 2 or less, more preferably 1500 g / m 2 or less (such as 1285 g / m 2 or 1299 g / m 2 or the like). Furthermore, each lower limit value of this adhesion amount can be combined with any of the upper limit values. The thickness of the back coat portion 10 is not particularly limited. For example, it can be 0.1 mm or more and 10.0 mm or less. More specifically, the lower limit value can be 0.1 mm or more, preferably 0.5 mm or more, more preferably 1.0 mm or more, and the upper limit value can be 10.0 mm or less, preferably 5.0 mm or less, more preferably 3.0 mm or less. Furthermore, each lower limit value of this thickness can be combined with any of the upper limit values. Next, the method for manufacturing the carpet 1 described so far will be explained in detail.

[0050] <Manufacturing method for carpet 1> As shown in Figure 3, the method for manufacturing the carpet 1 described above (hereinafter also referred to as "the manufacturing method") includes at least the flame retardancy imparting step P1, which will be described later. The manufacturing method may include a back-coating process P2, which will be described later. Here, if the manufacturing method includes a flame retardancy-granting step P1, it is considered the first embodiment, and if it includes a flame retardancy-granting step P1 and a back coat step P2, it is considered the second embodiment. In addition, the first and second embodiments of the manufacturing method may include a carpet forming step, which will be described later, before the flame retardancy imparting step P1.

[0051] <Flame retardant imparting process P1> As shown in Figure 3, the flame retardant imparting step P1 is a step of applying at least the flame retardant X described above to the carpet 1 (at least the pile 2) described above. In this flame retardant imparting process P1, the flame retardant X may be applied to the carpet 1 in a gelatinous state, with the first flame retardant X1 being solid at room temperature and the second flame retardant X2 being liquid at room temperature (especially a viscous material). Furthermore, in the flame retardancy imparting step P1, the first flame retardant X1 (such as guazinine sulfamate) may be used in the form of a dispersion liquid in a dispersion medium such as water before being mixed with other flame retardants X, etc. In this case, the concentration of each of the guazinine sulfamate, etc. ((weight of guazinine sulfamate, etc. / (weight of the dispersion liquid or solvent containing guazinine sulfamate, etc. and the dispersion medium)) × 100) may be any value, for example, 10% by weight or more and 70% by weight or less. More specifically, the lower limit may be 10% by weight or more, preferably 20% by weight or more, and more preferably 30% by weight or more, and the upper limit may be 70% by weight or less, preferably 60% by weight or less, and more preferably 50% by weight or less (such as 40% by weight). Furthermore, each of these lower limit values ​​of concentration may be combined with any of the upper limit values. The same applies to the second flame retardant X2. Before being mixed with other flame retardants X, each of the alkyl acid phosphate guanidine salts may be used in the form of a dispersion in a dispersion medium such as water. In this case, the concentration of the alkyl acid phosphate guanidine salt ((weight of alkyl acid phosphate guanidine salt / (weight of the dispersion of alkyl acid phosphate guanidine salt and the dispersion medium or the solution of the solvent)) × 100) may be any value, for example, 10% by weight or more and 70% by weight or less. More specifically, the lower limit may be 10% by weight or more, preferably 20% by weight or more, and more preferably 30% by weight or more, and the upper limit may be 70% by weight or less, preferably 60% by weight or less, and more preferably 50% by weight or less (40% by weight, etc.). Note that each of these lower limit values ​​of concentration may be combined with any of the upper limit values. Furthermore, the same applies to penetrant Y; each acetylene glycol-based penetrant before being mixed with other flame retardants may be used in the form of a dispersion liquid in a dispersion medium such as water. In this case, the concentration of the acetylene glycol-based penetrant ((weight of acetylene glycol-based penetrant / (weight of the dispersion liquid or solvent containing the acetylene glycol-based penetrant and the dispersion medium)) × 100) may be any value, for example, 20% by weight or more and 90% by weight or less. More specifically, the lower limit may be 20% by weight or more, preferably 40% by weight or more, and even more preferably 50% by weight or more, and the upper limit may be 90% by weight or less, preferably 80% by weight or less, and even more preferably 70% by weight or less (60% by weight, etc.). Note that each of these lower limits of concentration may be combined with any of the upper limits.

[0052] Here, the means of "applying" in the flame retardancy imparting process P1 are not particularly limited, but may include, for example, a spray method (also called spray coating), as well as padding (dip-nip method), dipping method, kiss roll method, foam processing method, coating method, dropping method, or printing method. The application of the flame retardant X in the flame retardant imparting step P1 may be carried out under an atmosphere at a predetermined temperature. The predetermined temperature for the application of the flame retardant X in the flame retardant imparting step P1 is not particularly limited. To elaborate on this application temperature, for example, it may be between 110°C and 150°C. More specifically, the lower limit may be 110°C or higher, preferably 120°C or higher, and even more preferably 125°C or higher, while the upper limit may be 150°C or lower, preferably 140°C or lower, and even more preferably 135°C or lower (e.g., 130°C). Furthermore, each of these lower limits of the application temperature may be combined with any of the upper limits.

[0053] To elaborate on the spray method described above, this method involves spraying (also called coating) a dispersion of a mixture of flame retardant X and liquid penetrating agent Y at a predetermined concentration in a dispersion medium such as water, or a solution dissolved in a solvent such as water, onto the surface 1a (also called the pile 2 side or pile surface) and / or the back surface 1b (the back surface 3b of the base fabric 3 or the back surface 10b of the back coat portion 10) of the carpet 1 in a mist form. Note that when coating the surface 1a and back surface 1b of the carpet 1 using the spray method, the order can be surface 1a → back surface 1b, or back surface 1b → surface 1a, or it may be done only on surface 1a or only on back surface 1b. Furthermore, in the case of the spray method, if the carpet 1 is a long piece with a width of approximately 3.5 to 3.6 m (roughly the width of a 6-tatami room), it may not fit into the water tank into which it is immersed in a dispersion of the flame retardant X mixture (i.e., the padding method or immersion method cannot be used). However, with the spray method, it can be said that application is possible regardless of the width of the carpet 1. Other means of "applying" include the padding method, in which a mixture of flame retardant X and other substances is dispersed at a predetermined concentration in a dispersion medium such as water, or a solution in which the carpet 1 is dissolved in a solvent such as water, is immersed in the dispersion liquid, and then the immersed carpet 1 is squeezed through a pair of mangles (padding rolls). However, the means of "applying" does not have to be the padding method that squeezes with mangles; it may also be an immersion method in which the carpet 1 is simply immersed in a solution in which the mixture is dissolved.

[0054] Here, when the mixture is dispersed in a dispersion medium after mixing the flame retardant X, etc., by a spray method or the like in the flame retardant imparting step P1, the overall concentration of the flame retardant X ((weight of flame retardant X / (weight of the dispersion liquid or solvent solution of the mixture of flame retardant X, etc., and the dispersion medium)) × 100) may be any value, but for example it may be 5% by weight or more and 60% by weight or less. More specifically, the lower limit may be 5% by weight or more, preferably 10% by weight or more, and even more preferably 15% by weight or more, and the upper limit may be 60% by weight or less, preferably 50% by weight or less, and even more preferably 40% by weight or less (20%, 25%, 50%, etc.). Note that each of these lower limits of concentration may be combined with any of the upper limits. Furthermore, the concentration of the first flame retardant X1 alone in this case ((weight of the first flame retardant X1 / (weight of the dispersion or solvent of the mixture of the first flame retardant X1 and other flame retardants X, etc., and the dispersion medium)) × 100) may be any value, but for example it may be 5% by weight or more and 60% by weight or less. More specifically, the lower limit may be 5% by weight or more, preferably 10% by weight or more, and even more preferably 15% by weight or more, and the upper limit may be 60% by weight or less, preferably 50% by weight or less, and even more preferably 40% by weight or less (20%, 25%, 50%, etc.). Furthermore, each of these lower limits of concentration may be combined with any of the upper limits. Furthermore, the concentration of the second flame retardant X2 alone in this case ((weight of the second flame retardant X2 / (weight of the dispersion or solvent of the mixture of the second flame retardant X2 and other flame retardants X, etc., and the dispersion medium)) × 100) may be any value, but for example, it may be 0.10% by weight or more and 10.00% by weight or less. More specifically, the lower limit may be 0.10% by weight or more, preferably 0.20% by weight or more, and even more preferably 0.40% by weight or more, and the upper limit may be 10.00% by weight or less, preferably 7.00% by weight or less, and even more preferably 4.00% by weight or less (0.5%, 0.75%, 1.25%, 2.00%, 2.50%, 3.75%, etc.). Note that each of these lower limits of concentration may be combined with any of the upper limits. Furthermore, the concentration of penetrant Y alone in this case ((weight of penetrant Y / (weight of the dispersion or solvent of the mixture of penetrant Y and flame retardant X, etc., and the dispersion medium)) × 100) can be any value, but for example, it may be 0.05% by weight or more and 10.00% by weight or less. More specifically, the lower limit may be 0.05% by weight or more, preferably 0.50% by weight or more, and even more preferably 1.00% by weight or more, and the upper limit may be 10.00% by weight or less, preferably 5.00% by weight or less, and even more preferably 3.00% by weight or less (e.g., 0.10% by weight). Note that each of these lower limits of concentration may be combined with any of the upper limits.

[0055] In addition, in the flame retardant imparting step P1, a mixture such as flame retardant X may be applied to the carpet 1, and the carpet 1 may be dried afterward. There are no particular limitations on the means of this "drying," but for example, the carpet 1 may be stretched with pin tenters and dried in a dryer at a predetermined drying temperature and for a predetermined drying time. The drying temperature is not particularly limited, but for example, it may be between 110°C and 150°C. More specifically, the lower limit may be 110°C or higher, preferably 120°C or higher, and even more preferably 125°C or higher, while the upper limit may be 150°C or lower, preferably 140°C or lower, and even more preferably 135°C or lower (e.g., 130°C). Furthermore, each of these lower limits of the drying temperature may be combined with any of the upper limits. There are no particular limitations on the drying time, but for example, it may be between 0.1 minutes (6 seconds) and 360.0 minutes. More specifically, the lower limit may be 0.1 minutes or more, preferably 0.2 minutes (12 seconds) or more, and even more preferably 1.0 minute or more, while the upper limit may be 360.0 minutes or less, preferably 10.0 minutes or less, and even more preferably 5.0 minutes or less (such as 2.0 minutes). Furthermore, each of these lower limits of drying time may be combined with any of the upper limits. In addition, the means of "drying" in the flame retardant application step P1 may be natural drying, blowing drying (air drying), etc. Even when the means of "drying" in the flame retardant application step P1 is natural drying or the like, the drying temperature is not particularly limited. For example, it may be normal temperature (about 20 °C, etc.), and the drying time may be until the moisture evaporates from the carpet 1 (for example, 24 hours, etc.).

[0056] The total amount of the flame retardant X applied after drying in the flame retardant application step P1 (that is, the dry weight of the flame retardant X on the carpet 1) is not particularly limited. For example, it may be 1.00 g / m 2 to 300.00 g / m 2 or less. More specifically, the lower limit value may be 1.00 g / m 2 or more, preferably 20.00 g / m 2 or more, more preferably 40.00 g / m 2 or more, and the upper limit value may be 300.00 g / m 2 or less, preferably 200.00 g / m 2 or less, more preferably 100.00 g / m 2 or less (40.00 g / m 2 or 52.80 g / m 2 or 66.00 g / m 2 or 67.32 g / m 2 or 67.95 g / m 2 or 69.30 g / m 2 or 71.28 g / m 2 or 72.60 g / m 2 or 75.90 g / m 2 or 89.10 g / m 2 or 132.00 g / m 2 etc.) may be acceptable. Note that each lower limit value of this application amount may be combined with any of the upper limit values. Note also that the amount of the first flame retardant X1 applied only after drying in the flame retardant application step P1 (that is, the dry weight of the first flame retardant X1 on the carpet 1) is not particularly limited. For example, it may be 5.00 g / m 2 to 300.00 g / m 2 or less. More specifically, the lower limit value may be 5.00 g / m 2Preferably 10.00 g / m 2 More preferably 20.00 g / m 2 If it is above that, or if the upper limit is 300.00 g / m³ 2 Preferably, 200.00 g / m 2 More preferably, 100.00 g / m 2 Below (40.00g / m 2 or 52.80 g / m 2 66.00 g / m 2 82.50 g / m 2 132.00 g / m 2 It is also acceptable for it to be such as (etc.). Furthermore, each of the lower limits of this grant amount may be combined with any of the upper limits. Furthermore, the amount of the second flame retardant X2 applied after drying in the flame retardant imparting process P1 (i.e., the dry weight of the second flame retardant X2 in the carpet 1) is not particularly limited, but for example, 0.10 g / m 2 More than 30.00g / m 2 The following is also acceptable, and to elaborate further, the lower limit is 0.10 g / m³. 2 Preferably 1.00 g / m 2 More preferably 1.50 g / m 2 If the value is above that, or if the upper limit is 30.00 g / m³ 2 Preferably 20.00 g / m 2 More preferably, 10.00 g / m 2 Below (1.38g / m 2 or 1.98g / m 2 3.30 g / m 2 5.28 g / m 2 6.60 g / m 2 9.90g / m 2 It is also acceptable for it to be such as (etc.). Furthermore, each of the lower limits of this grant amount may be combined with any of the upper limits. Furthermore, the amount of penetrating agent Y applied after drying in the flame retardant imparting process P1 (i.e., the dry weight of penetrating agent Y in carpet 1) is not particularly limited, but for example, 0.01 g / m 2 More than 5.00g / m 2 The following is also acceptable, and to elaborate further, the lower limit is 0.01 g / m³. 2Preferably 0.05 g / m 2 More preferably 0.10 g / m 2 If it is above that, or if the upper limit is 5.00 g / m 2 Preferably, 2.00 g / m 2 More preferably, 1.00 g / m 2 Below (0.40g / m 2 or 0.50g / m 2 It is also acceptable for it to be such as (etc.). Furthermore, each of the lower limits of this grant amount may be combined with any of the upper limits.

[0057] Here, the amount of flame retardant X applied (adhered) after drying in the flame retardant imparting process P1 can also be said to be the sum of the amount of the first flame retardant X1 applied (adhered) and the amount of the second flame retardant X2 applied (adhered). On the other hand, there are no particular limitations on the amount of flame retardant X applied before drying in the flame retardant imparting process P1 (i.e., the wet weight of flame retardant X in carpet 1), but for example, 10 g / m 2 More than 3000g / m 2 The following is also acceptable, and to elaborate further, the lower limit is 10g / m 2 Preferably 250 g / m² 2 More preferably 500 g / m² 2 If it is above that, or if the upper limit is 3000g / m³ 2 Preferably 2000 g / m² 2 More preferably, 1000 g / m² 2 Below (660g / m 2 or 825g / m 2 It is also acceptable for it to be such as (etc.). Furthermore, each lower limit of the wet weight adhesion amount may be combined with any of the upper limits. In such a flame retardant imparting process P1, when the first flame retardant X1 and the second flame retardant X2 described above are applied to the pile 2 and base fabric 3 and adhere to the surface of the fibers used in the pile 2 and base fabric 3, if the first flame retardant X1 is solid and in particulate form at room temperature (and atmospheric pressure), and the second flame retardant X2 is liquid (especially a viscous material) at room temperature (and atmospheric pressure), <1> In a state where only the first flame retardant X1 is directly attached to the surface of the fiber, <2> The first flame retardant X1 is directly attached to the surface of the fiber, and the second flame retardant X2 is attached to the first flame retardant X1, surrounding it in a roughly layered manner when viewed in a side cross-section. <3> The first flame retardant X1 is attached to the fiber surface via a second flame retardant X2 that is attached in a roughly layered manner when viewed in a side cross-section. <4> Only the second flame retardant X2 is adhering to the fiber surface in a roughly layered manner when viewed in a side cross-section. <5> It can be said that the surface of the fiber may be in a state where nothing is attached to it (see Figure 1).

[0058] <Back coating process P2> As shown in Figure 3(b), the back coat process P2 is a process that, after the flame retardant imparting process P1 described above, provides a back coat portion 10 to the back surface 3b of the base fabric 3, which is coated with a backing material containing rubber such as styrene-butadiene rubber or a filler, in an atmosphere at a predetermined temperature. Furthermore, while there are no particular limitations on the specified temperature for applying the backing material in the back coat process P2, it may be the same as when "applying" it in the flame retardant application process P1 described above.

[0059] Here, the means of "coating" in the backcoat process P2 are not particularly limited, but may be, for example, application. Specific means of application include application with a brush, spray application, or using methods such as the comma direct method, gravure direct method, gravure reverse method, reverse roll coating method, air knife coating method, kiss coating method, etc., or using a thin film coater, roll printing machine, inkjet printing machine, rotor dampening, etc. Other means of "coating" may include the kiss roll method, foam processing method, etc. Furthermore, when coating the backing material in the back coating process P2, the powdered backing material is dispersed in a dispersion medium such as water at a predetermined concentration, or a solution is obtained by dissolving the powdered backing material in a solvent such as water, and this is coated onto the back surface 3b of the base fabric 3 by application or other means. Furthermore, in the back coat process P2, the carpet 1 may be dried after coating with the mixture. In this case, there are no particular limitations on the means of drying, drying temperature, drying time, etc., but they may be the same as those used in the flame retardancy imparting process P1 described above.

[0060] Here, in the back coat process P2, the rubber, such as styrene-butadiene rubber, among the backing materials, may be used in the form of a dispersion liquid in a dispersion medium such as water before being mixed with other fillers, etc. In this case, the concentration of the rubber, such as styrene-butadiene rubber ((weight of the rubber, such as styrene-butadiene rubber / (weight of the dispersion liquid or solvent containing the rubber, such as styrene-butadiene rubber)) × 100) may be any value, for example, 15% by weight or more and 75% by weight or less. More specifically, the lower limit may be 15% by weight or more, preferably 25% by weight or more, and even more preferably 35% by weight or more, and the upper limit may be 75% by weight or less, preferably 65% ​​by weight or less, and even more preferably 55% by weight or less (44% by weight, etc.). Note that each of these lower limits of concentration may be combined with any of the upper limits. This also applies to acrylic acid, a thickener among the other backing materials. The thickener may be used in the form of a dispersion in a dispersion medium such as water before being mixed with other fillers, and the concentration of the thickener in this case ((weight of thickener / (weight of the dispersion of the thickener and the dispersion medium or the solution of the solvent)) × 100) may be any value, for example, 10% by weight or more and 70% by weight or less. More specifically, the lower limit may be 10% by weight or more, preferably 20% by weight or more, and even more preferably 30% by weight or more, and the upper limit may be 70% by weight or less, preferably 60% by weight or less, and even more preferably 50% by weight or less (such as 40% by weight). Note that each of these lower limits of concentration may be combined with any of the upper limits.

[0061] The amount of backing material added after drying in the backcoat process P2 (i.e., the dry weight of the backing material in carpet 1) is not particularly limited, but for example, 500 g / m 2 More than 3000g / m 2 The following is also acceptable, and to elaborate further, the lower limit is 500g / m 2 Preferably 700 g / m² 2 More preferably 900 g / m² 2 If it is above that, or if the upper limit is 3000g / m³ 2 Preferably 2000 g / m² 2 More preferably, 1400 g / m² 2 Below (1285g / m 2 or 1299g / m 2 It is also acceptable for it to be such as (etc.). Furthermore, each of the lower limits of this grant amount may be combined with any of the upper limits. Furthermore, there are no particular limitations on the amount of rubber such as styrene-butadiene rubber added after drying in the backcoat process P2 (i.e., the dry weight of rubber such as styrene-butadiene rubber in carpet 1), but for example, 50 g / m 2 More than 2000g / m 2 The following is also acceptable, and to elaborate further, the lower limit is 50g / m 2 Preferably 100 g / m² 2 More preferably 200 g / m² 2If it is above that, or if the upper limit is 2000g / m³ 2 Preferably 1500 g / m² 2 More preferably, 1000 g / m² 2 Below (343g / m 2 or 347g / m 2 It is also acceptable for it to be such as (etc.). Furthermore, each of the lower limits of this grant amount may be combined with any of the upper limits. Furthermore, there are no particular limitations on the amount of filler applied after drying in the backcoat process P2 (i.e., the dry weight of the filler in carpet 1), but for example, 100g / m 2 More than 3000g / m 2 The following is also acceptable, and to elaborate further, 100g / m 2 Preferably 200 g / m² 2 More preferably 500 g / m² 2 If it is above that, or if the upper limit is 3000g / m³ 2 Preferably 2500 g / m² 2 More preferably, 2000 g / m² 2 Below (942g / m 2 952g / m² 2 It is also acceptable for it to be such as (etc.). Furthermore, each of the lower limits of this grant amount may be combined with any of the upper limits. Here, the amount of backing material applied (adhered) after drying in the back coat process P2 can be said to be the sum of the amount of rubber applied (adhered), such as styrene-butadiene rubber, and the amount of filler applied (adhered).

[0062] Furthermore, there are no particular limitations on the ratios of rubber such as styrene-butadiene rubber and fillers in the backing material applied in the back coat process P2. However, if expressed in parts by weight, the amount of rubber such as styrene-butadiene rubber may be, for example, 15 parts by weight or more and 75 parts by weight or less. More specifically, the lower limit may be 15 parts by weight or more, preferably 25 parts by weight or more, and even more preferably 35 parts by weight or more, while the upper limit may be 75 parts by weight or less, preferably 65 parts by weight or less, and even more preferably 55 parts by weight or less (such as 45 parts by weight). Moreover, each of these lower limits in parts by weight may be combined with any of the upper limits. Furthermore, there are no particular limitations on the amount of filler such as calcium carbonate by weight, but for example, it may be 25 parts by weight or more and 85 parts by weight or less. More specifically, the lower limit may be 25 parts by weight or more, preferably 35 parts by weight or more, and even more preferably 45 parts by weight or more, and the upper limit may be 85 parts by weight or less, preferably 75 parts by weight or less, and even more preferably 65 parts by weight or less (such as 55 parts by weight). Note that each of these lower limits by weight may be combined with any of the upper limits. Furthermore, there are no particular limitations on the amount of thickener such as acrylic acid by weight, but for example, it may be 0.1 parts by weight or more and 10.0 parts by weight or less. More specifically, the lower limit may be 0.1 parts by weight or more, preferably 0.2 parts by weight or more, and even more preferably 0.5 parts by weight or more, and the upper limit may be 10.0 parts by weight or less, preferably 5.0 parts by weight or less, and even more preferably 2.0 parts by weight or less (such as 1.0 part by weight). Note that each of these lower limits by weight may be combined with any of the upper limits. Furthermore, there are no particular limitations on the amount of ammonia by weight, but for example, it may be between 0.01 parts by weight and 5.00 parts by weight. More specifically, the lower limit may be 0.01 parts by weight or more, preferably 0.10 parts by weight or more, and even more preferably 0.20 parts by weight or more, while the upper limit may be 5.00 parts by weight or less, preferably 2.00 parts by weight or less, and even more preferably 1.00 part by weight or less (e.g., 0.50 parts by weight). Note that each of these lower limits by weight may be combined with any of the upper limits.

[0063] <Carpet Forming Process> The carpet formation process is a process of forming the carpet before the flame retardancy imparting process P1 described above. As mentioned above, carpets can be pile woven, pile knitted, or tufted carpets. If a carpet is pile woven, the carpet formation process can be described as a pile woven fabric weaving process. If a carpet is pile knitted, the carpet formation process can be described as a pile knitted fabric knitting process. If a carpet is tufted carpet, the carpet formation process can be described as a tufted carpet formation process.

[0064] In the pile fabric weaving process, the pile fabric woven in this process may be made by, for example, weaving a pair of upper and lower fabrics, each woven with plain weave, twill weave, satin weave, etc., with pile threads connecting them in the warp direction, and then cutting the connecting threads approximately in the middle (center cut). As a result, two pile fabrics are simultaneously created, with the upper or lower fabric as the base fabric 3 and each of the cut connecting threads (pile threads) as the pile 2. A pile fabric with this configuration is also called a moquette, and in this case, it is woven using a double moquette loom (such as a jacquard loom or dobby loom). Alternatively, instead of weaving the upper and lower fabrics together with pile threads, the moquette may be woven together with a single fabric, with the pile threads in the warp direction hooked onto wires extending in the weft direction. In this case, it is woven using a wire moquette loom. Furthermore, in the case of a pile knitting process, the pile knitting process may involve using, for example, a knitted fabric (a type of warp knit, also called Denby knit or tricot) made by knitting the warp threads on a knitting machine with a predetermined number of reeds (e.g., 3), as the base fabric 3, and then raising one or both sides of this base fabric 3 to form the pile 2. Furthermore, in the case of the tufted carpet formation process, the tufted carpet formed in this process is formed, for example, by a tufting machine that tufts (plants) piles 2 onto a base fabric 3 at predetermined intervals. [Examples]

[0065] From here on, we will refer to Examples 1 to 4, Example 1', Comparative Examples 1 to 3, and Reference Examples 1 to 5 of the carpet 1 according to the present invention. These examples, comparative examples, and reference examples will be used to conduct Tests 1 and 2, which will be described later.

[0066] <Example 1, Example 1'> Carpet 1 in Example 1 is a carpet in which only nylon 6 fibers are used for the pile 2 and only polypropylene fibers are used for the base fabric 3, and is a pile fabric (mocket) woven in the carpet formation process (pile fabric weaving process). The overall weight of carpet 1 is 1018 g / m². 2 The pile weight of Pile 2 is 907g / m 2 The base fabric 3 has a basis weight of 111 g / m². 2 That was the case. In the flame retardant imparting process P1, a dispersion was prepared by mixing a first flame retardant X1 consisting only of sulfamic acid guazinine (Non-nen WS-3 manufactured by Marubishi Yuka Kogyo Co., Ltd.) and a second flame retardant X2 consisting only of alkyl acid phosphate guanidine salt (32-han manufactured by Marubishi Yuka Kogyo Co., Ltd.) with a penetrating agent Y consisting only of acetylene glycol (Orfin PD-002W manufactured by Nisshin Chemical Industry Co., Ltd.), and then dispersing the mixture with water as a dispersion medium. This dispersion was applied to the back surface 1b of the carpet 1 by spraying, and then to the front surface 1a (pile 2) of the carpet 1. After that, the carpet was dried in a dryer while stretched with pin tenters. Following the flame retardancy imparting step P1, in the back coat step P2, a dispersion liquid, obtained by dispersing styrene-butadiene rubber and calcium carbonate as a filler in water as a dispersion medium, onto the back surface 3b of the pile fabric base fabric 3 was applied by coating to create the back coat portion 10, resulting in the carpet 1 of Example 1. In this step, the total amount of dispersion applied (coated) in the flame retardant imparting process P1 was 660.0 g / m². 2In this dispersion, the total weight percentage of flame retardant X is 27.00%, the weight percentage of the first flame retardant X1 (guazinine sulfamate) is 25.00%, the weight percentage of the second flame retardant X2 (guanidine salt of alkyl acid phosphate ester) is 2.00%, the weight percentage of penetrating agent Y is 0.10%, and the weight percentage of water, which is the dispersion medium, is 72.90%. The total amount of the dispersion applied (coated) in the back coat process P2, as well as the weight percentages of styrene-butadiene rubber, calcium carbonate, and water in the dispersion, are predetermined values. As a result, the total amount of flame retardant X applied to carpet 1 in Example 1 was 71.28 g / m² by dry weight. 2 The amount of the first flame retardant X1 applied was 66.00 g / m². 2 The amount of the second flame retardant X2 applied was 5.28 g / m². 2 The amount of penetrating agent Y applied was 0.40 g / m². 2 Furthermore, the total amount of backing material attached was 1285.00 g / m². 2 The amount of styrene-butadiene rubber adhering to the surface was 343.00 g / m². 2 The amount of calcium carbonate deposited was 942.00 g / m². 2 That's what happened. In addition, in the carpet 1 of Example 1, a mixture consisting only of flame retardant X and without penetrating agent Y was used. In the flame retardant imparting step P1, the weight percentage of penetrating agent Y was set to 0.00% of the total dispersion liquid applied (coated), and the weight percentage of water, which is the dispersion medium, was set to 73.00% to obtain carpet 1 of Example 1'. As a result, compared to carpet 1 of Example 1', the total amount of flame retardant X applied to carpet 1 of Example 1 was 71.28 g / m² by dry weight. 2 The total amount of the first flame retardant X1 applied was 66.00 g / m². 2 The amount of the second flame retardant X2 applied was 5.28 g / m². 2 So, it's the same, but the amount of penetrating agent Y that adheres is 0.00g / m 2 The difference lies in the fact that this became the case.

[0067] <Example 2> In Carpet 1 of Example 1, the first flame retardant X1 consisted of guazinine sulfamate and a mixture of ammonium sulfate and phosphorus-nitrogen-based onium salt (Non-nen WS-29 manufactured by Marubishi Oil & Chemical Co., Ltd.). In the flame retardant application process P1, the total weight percentage of the dispersion liquid to be applied (coated) was 25.00%, the same as in Example 1. However, the weight percentage of guazinine sulfamate was set to 5.00%, and the weight percentage of the mixture of ammonium sulfate and phosphorus-nitrogen-based onium salt was set to 20.00%, resulting in Carpet 1 of Example 2. As a result, compared to carpet 1 of Example 1, carpet 1 of Example 2 had a total amount of the first flame retardant X1 attached by dry weight of 66.00 g / m². 2 So, it's the same, but the amount of sulfamic acid guazinine attached is 13.20 g / m 2 The amount of adhesion of the mixture of ammonium sulfate and phosphorus-nitrogen-based onium salt was 52.80 g / m². 2 The difference lies in the fact that this became the case.

[0068] <Example 3> In the carpet 1 of Example 2, the means of applying the dispersion in the flame retardancy imparting step P1 is simply by spraying, applying it to the surface 1a side (pile 2 side) of the carpet 1, and the total amount of dispersion applied (coated) in the flame retardancy imparting step P1 is 825.0 g / m². 2 Carpet 1 of Example 3 was used as the example. As a result, compared to carpet 1 in Example 2, carpet 1 in Example 3 had a total amount of flame retardant X attached by dry weight of 89.10 g / m². 2 The total amount of the first flame retardant X1 applied was 82.50 g / m². 2 The amount of sulfamic acid guazinine attached was 16.50 g / m². 2 The amount of adhesion of the mixture of ammonium sulfate and phosphorus-nitrogen-based onium salt was 66.00 g / m². 2 The amount of the second flame retardant X2 applied was 6.60 g / m². 2 The amount of penetrating agent Y applied was 0.50 g / m². 2 The difference lies in the fact that this became the case.

[0069] <Example 4> In the carpet 1 of Example 2, the means of applying the dispersion in the flame retardancy imparting step P1 was changed to simply applying it to the surface 1a side (pile 2 side) of the carpet 1 by spraying, resulting in the carpet 1 of Example 4. Furthermore, compared to Carpet 1 of Example 2, Carpet 1 of Example 4 had the same dry weight as Carpet 1 of Example 2 in terms of the total amount of the first flame retardant X1, the amount of guazinine sulfamate, and the amount of the mixture of ammonium sulfate and phosphorus-nitrogen-based onium salt.

[0070] <Comparative Example 1> In the carpet 1 of Example 1, the flame retardant X was made up of only a first flame retardant X1 consisting solely of sulfamic acid guazinine, and the means of applying the dispersion in the flame retardant imparting step P1 was to apply it only to the surface 1a side (pile 2 side) of the carpet 1 by spraying, and the weight percentage of the first flame retardant X1 as a whole in the total dispersion applied (coated) in the flame retardant imparting step P1 was set to 20.00%, and the weight percentage of water as the dispersion medium was set to 80.00%, and the carpet of Comparative Example 1 was obtained by changing the total amount of dispersion applied in the back coat step P2, as well as the weight percentages of styrene butadiene rubber, calcium carbonate, and water. As a result, the carpet of Comparative Example 1 had a dry weight of 52.80 g / m² of sulfamic acid guazinine, which is the total amount of flame retardant X, compared to carpet 1 of Example 1. 2 The total amount of backing material attached was 1299.00 g / m². 2 The amount of styrene-butadiene rubber adhering to the surface was 347.00 g / m². 2 The amount of calcium carbonate deposited was 952.00 g / m². 2 The difference lies in the fact that this became the case.

[0071] <Comparative Example 2> In the carpet of Comparative Example 1, the weight percentage of the first flame retardant X1 in the entire dispersion applied (coated) in the flame retardant imparting step P1 was set to 25.00%, and the weight percentage of water, which is the dispersion medium, was set to 75.00%, resulting in the carpet of Comparative Example 2. As a result, the carpet of Comparative Example 2 had a dry weight of 66.00 g / m² of sulfamic acid guazinine, which is the total amount of flame retardant X, compared to the carpet of Comparative Example 1. 2 The difference lies in the fact that this became the case.

[0072] <Comparative Example 3> In the carpet of Comparative Example 1, the weight percentage of the first flame retardant X1 in the entire dispersion applied (coated) in the flame retardant imparting process P1 was set to 50.00%, and the weight percentage of water, which is the dispersion medium, was set to 50.00%, resulting in the carpet of Comparative Example 3. As a result, the carpet of Comparative Example 3 had a dry weight of 132.00 g / m² of sulfamic acid guazinine, which is the total amount of flame retardant X, compared to the carpet of Comparative Example 1. 2 The difference lies in the fact that this became the case.

[0073] <Reference example 1> In the carpet of Comparative Example 2, the flame retardant X is provided not only as the first flame retardant X1, which is guazinine sulfamate, but also as a second flame retardant X2 consisting only of the guanidine salt of an alkyl acid phosphate ester. In the flame retardant imparting step P1, the weight percentage of the first flame retardant X1 in the entire dispersion applied (coated) is 25.00%, the same as in Example 1, but the weight percentage of the second flame retardant X2 is set to 0.50%, and the weight percentage of water, which is the dispersion medium, is set to 74.50%, resulting in the carpet of Reference Example 1. As a result, the amount of the first flame retardant X1 applied to the carpet in Reference Example 1 was 66.00 g / m² by dry weight, compared to the carpet in Comparative Example 2. 2 So, it's the same, but the total amount of flame retardant X applied is 67.32 g / m 2 The amount of the second flame retardant X2 applied was 1.32 g / m². 2 The difference lies in the fact that this became the case.

[0074] <Reference example 2> In the carpet of Reference Example 1, the weight percentage of the second flame retardant X2 in the entire dispersion applied (coated) in the flame retardant imparting process P1 was set to 0.75%, and the weight percentage of water, which is the dispersion medium, was set to 74.25%, resulting in the carpet of Reference Example 2. As a result, the carpet in Reference Example 2 had a total amount of flame retardant X attached by dry weight of 67.98 g / m² compared to the carpet in Reference Example 1. 2 The amount of the second flame retardant X2 applied was 1.98 g / m². 2 The difference lies in the fact that this became the case.

[0075] <Reference example 3> In the carpet of Reference Example 1, the weight percentage of the second flame retardant X2 in the entire dispersion applied (coated) in the flame retardant imparting process P1 was set to 1.25%, and the weight percentage of water, which is the dispersion medium, was set to 73.75%, resulting in the carpet of Reference Example 3. As a result, the carpet in Reference Example 3 had a total amount of flame retardant X applied by dry weight of 69.30 g / m² compared to the carpet in Reference Example 1. 2 The amount of the second flame retardant X2 applied was 3.30 g / m². 2 The difference lies in the fact that this became the case.

[0076] <Reference example 4> In the carpet of Reference Example 1, the weight percentage of the second flame retardant X2 in the flame retardant imparting process P1 of the entire dispersion liquid was set to 2.50%, and the weight percentage of water, which is the dispersion medium, was set to 72.50%, resulting in the carpet of Reference Example 4. As a result, the carpet in Reference Example 4 had a total amount of flame retardant X applied by dry weight of 72.60 g / m² compared to the carpet in Reference Example 1. 2 The amount of the second flame retardant X2 applied was 6.60 g / m². 2 The difference lies in the fact that this became the case.

[0077] <Reference example 5> In the carpet of Reference Example 1, the weight percentage of the second flame retardant X2 in the flame retardant imparting process P1 of the entire dispersion liquid was set to 3.75%, and the weight percentage of water, which is the dispersion medium, was set to 71.25%, resulting in the carpet of Reference Example 5. As a result, the carpet in Reference Example 5 had a total amount of flame retardant X applied by dry weight of 75.90 g / m² compared to the carpet in Reference Example 1. 2 The amount of the second flame retardant X2 applied was 9.90 g / m². 2 The difference lies in the fact that this became the case.

[0078] <Test 1 (Flame Retardancy Test)> In Test 1, the carpets of Examples 1-3 and Comparative Examples 1-3 described above will be subjected to a test in accordance with the railway vehicle material flammability test (described in the commentary on the technical standards for vehicles by the Japan Railway Rolling Stock and Machinery Association and the Ministry of Land, Infrastructure, Transport and Tourism; hereinafter referred to as "the said flammability test"), and the pass / fail judgment will be compared based on whether the flame during alcohol combustion exceeds the top of the test piece, whether there is any afterflame or residue after alcohol combustion, and whether carbonization or deformation reaches the top of the test piece (if not, the unit of the value is mm). If the result is a pass / fail judgment, it will be indicated as "○" in Table 1, and if it is a fail, it will be indicated as "×" in Table 1. Furthermore, in Example 1' and other cases where penetrating agent Y was not used, the flame retardancy was determined by checking the elemental distribution of the flame retardant X on pile 2 and base fabric 3 using X-ray fluorescence analysis. The measurement results for Test 1 are shown in Table 1 and Figure 2 below.

[0079] [Table 1]

[0080] <Evaluation of Test 1 (Flame Retardancy Test)> As shown in Table 1, in Comparative Examples 1 to 3, even though the amount of the first flame retardant X1 applied was significantly increased, the second flame retardant X2, etc., was not used. As a result, the flame during alcohol combustion exceeded the upper edge of the test piece, and afterburners and dust remained after alcohol combustion, causing carbonization and deformation to reach the upper edge of the test piece. Therefore, the flammability test was judged as "×". In contrast, in Examples 1 to 3, although the amount of the first flame retardant X1 applied was not as large as in Comparative Example 3, the use of the second flame retardant X2 and the penetrating agent Y allowed the entire flame retardant X to adhere firmly to the pile 2 and base fabric 3. As a result, the flame during alcohol combustion did not exceed the upper edge of the test piece, there was no afterflame or dust after alcohol combustion, carbonization and deformation did not reach the upper edge of the test piece, and the carbonization and deformation that occurred was 60 mm or less, resulting in a "○" rating for the flammability test. In particular, in Example 1, the first flame retardant X1 did not contain ammonium sulfate or a mixture of ammonium sulfate and phosphorus-nitrogen-based onium salts, but consisted only of guazinine sulfamate, yet the flammability test was passed. This indicates that the first flame retardant X1 should contain at least guazinine sulfamate. Furthermore, in Example 1', although the amount of the first flame retardant X1 applied is not very large and the penetrating agent Y is not used, the second flame retardant X2 is used. As shown in Figure 2, the first flame retardant X1, guazinine sulfamate (containing sulfur (S), etc.), adheres firmly to the tip and base of the pile 2 and the surface of the base fabric 3. Therefore, it can be said that the same flammability test as Examples 1-3 results in a "○" rating. The reason why the amount of sulfur etc. appears small in the middle part of the pile 2 is that the dispersion applied in the flame retardant imparting process P1 adhered to the middle part of the pile 2 before drying, but due to migration such as moisture movement during drying, the sulfur etc. moved to the tip and base of the pile 2. However, even after drying, a predetermined amount of sulfur adheres to the middle part of the pile 2, so it can be said that there is no problem in the flammability test. Furthermore, although the amount of the first flame retardant X1 applied in Example 4 is the same as in Example 1, the means of applying the dispersion in the flame retardant imparting step P1 is simply by spraying it onto the surface 1a side of the carpet 1. Since the second flame retardant X2 is also used, as in Example 1', the first flame retardant X1, which is guazinine sulfamate, and the mixture of ammonium sulfate and phosphorus-nitrogen-based onium salt adhere firmly to the tips and base ends of the pile 2 and the surface side of the base fabric 3. Therefore, it can be said that the same flammability test as in Examples 1 to 3 will result in a "○" rating. Therefore, by using not only the first flame retardant X1 but also the second flame retardant X2, even a nylon 6-pile carpet can be made flame-retardant.

[0081] <Test 2 (Test of whitening inhibition and tackiness)> In Test 2, the evaluation of the whitening suppression property will be compared for the carpets of Reference Examples 1-5 and Examples 1-4, Example 1', and Comparative Examples 1-3, based on the evaluation of the state in which white powder was generated. In this evaluation, if no white powder was generated on the pile side of the carpet (the side formed by the tips of multiple piles), it will be considered a pass (indicated as "○" in Table 2), and if powder was generated, it will be considered a fail (indicated as "×" in Table 2). Regarding <tackiness>, the pile surface condition evaluation will be compared for the carpets of Reference Examples 1-5, Examples 1-4, and Comparative Examples 1-3. In this condition evaluation, a "○" indicates that no stickiness has occurred on the pile surface of the carpet, and a "×" indicates that stickiness has occurred. The measurement results for Test 2 are shown in Table 2 below.

[0082] [Table 2]

[0083] <Evaluation of Test 2 (Test of Whitening Inhibition and Tackiness)> As shown in Table 2, for Comparative Examples 1 to 3, in which the second flame retardant X2 was not used, Comparative Example 1 received a "○" rating for both whitening suppression and tackiness because the amount of the first flame retardant X1 applied was not very large. However, in Comparative Examples 2 and 3, the amount of the first flame retardant X1 applied was significantly increased, resulting in a "×" rating for whitening suppression. On the other hand, among Reference Examples 1 to 5, in which the second flame retardant X2 is used, Reference Example 1 received a "×" rating for whitening suppression because the amount of the second flame retardant X2 applied was insufficient, and Reference Example 5 received a "×" rating for tackiness because the amount of the second flame retardant X2 applied was too large. In contrast, in Reference Examples 2-4, the amount of the second flame retardant X2 applied is appropriate in relation to the first flame retardant X1 (the ratio of the first flame retardant X1 to the second flame retardant X2 is 132:3 to 132:14), so both the whitening suppression and tackiness are rated as "○". This also applies to Examples 1 to 4 and Example 1', in which the flammability test in Test 1 above resulted in a "○" rating. In these examples, the ratio of the first flame retardant X1 to the second flame retardant X2 is within the range of 132:3 to 132:14 (in particular, in Example 3, the ratio of the first flame retardant X1 to the second flame retardant X2 is 16.50 + 66.00:6.60 = 82.50:6.60 = 132.00:10.56, which is within the range of 132:3 to 132:14). Therefore, by setting the ratio of the amount of the first flame retardant X1 to the second flame retardant X2 to 132:3 to 132:14, it is possible to achieve both "whitening suppression" and "tack reduction".

[0084] <Other> The present invention is not limited to the embodiments described above. The individual components of the carpet 1, the flame retardant X, the method for manufacturing the carpet 1, etc., as well as the overall structure, shape, dimensions, etc., can be modified as appropriate in accordance with the spirit of the present invention. The carpet 1 does not necessarily have to have a backcoat portion 10. The base fabric 3 does not necessarily have to be made of polypropylene fibers; it may be made of other polyolefin fibers such as polyethylene fibers, polyester fibers such as polyethylene terephthalate fibers, nylon (polyamide) fibers such as nylon 6 fibers or nylon 66 fibers, or any of these individually or in combination. The first flame retardant X1 does not necessarily have to contain ammonium sulfate or a mixture of ammonium sulfate and phosphorus-nitrogen-based onium salts. The base fabric 3 does not need to have flame retardant X attached to it. The ratio of the amount of the first flame retardant X1 to the amount of the second flame retardant X2 applied does not have to be 132:3 to 132:14 (132 / 14 (≒9.429) or more and 132 / 3 (=44.000) or less); it may be less than 132 / 14 or greater than 132 / 3. At least the pile 2 (i.e., pile 2 alone, or pile 2 and base fabric 3) does not need to have penetrating agent Y attached to it, and even if at least the pile 2 has penetrating agent Y attached to it, the penetrating agent Y does not need to contain an acetylene glycol-based penetrating agent. The second flame retardant X2 does not need to be a viscous material at room temperature. In the method for manufacturing carpet 1, the flame retardant X may be applied to at least the pile 2 by means other than spray application, and may also be applied by means such as padding or immersion. In the flame retardant imparting process P1, when the first flame retardant X1 and the second flame retardant X2 described above are applied to the pile 2 and base fabric 3 and adhere to the surface of the fibers used in the pile 2 and base fabric 3, if the first flame retardant X1 is solid and in particulate form at room temperature (and atmospheric pressure), the second flame retardant X2 is liquid (especially in a viscous form) at room temperature (and atmospheric pressure), and the penetrating agent Y is liquid at room temperature (and atmospheric pressure), then the above <1> ~ <5> In addition, it can be said that the second flame retardant X2 may adhere to the fiber surface in a roughly layered manner when viewed in a side cross-section, covering the first flame retardant X1 which is attached to the fiber surface directly or via the second flame retardant X2, or the penetrating agent Y which is attached to the fiber surface in a roughly layered manner when viewed in a side cross-section.

[0085] Carpet 1 may optionally contain extender pigments or fillers such as titanium dioxide and calcium carbonate, or materials to which deodorizers, antibacterial agents, antifungal agents, flame retardants, water repellents, stain repellents, colorants, fragrances, foaming agents, dispersants, etc., may be added. Carpet 1 can be any color, including black, brown, blue, white, red, orange, yellow, green, or purple, and its saturation and brightness can be any value. The pattern of Carpet 1 can also be any, such as a solid color, a plant pattern (flowers or plants), an animal pattern, a geometric pattern, or a pattern created by surface irregularities. [Industrial applicability]

[0086] The carpet according to the present invention, and the carpet manufactured by the method for manufacturing the carpet according to the present invention, can be used as flooring in the interiors of vehicles such as railway cars, automobiles (passenger cars), aircraft, and ships, and can also be used as flooring in the interiors of buildings such as houses and office buildings, and may also be used for industrial materials, and for everyday materials such as shoes and clothing. The flame retardant according to the present invention can be applied not only to carpets, but also to interior materials (interior wall materials, ceiling materials, floor materials, etc.) inside vehicles such as railway cars, automobiles (passenger cars), aircraft, and ships, or to surface materials (seat covers) that cover chairs (seats), or to interior materials (interior wall materials, ceiling materials, floor materials, etc.) inside buildings such as houses and office buildings, or to surface materials (cover materials) that cover furniture such as chairs and beds, lighting fixtures, etc. Furthermore, it can be applied to any material, including textile products, industrial materials, and everyday materials such as shoes and clothing. [Explanation of symbols]

[0087] 1 Carpet 2 piles 3 Base fabric X Flame retardant X1 First Flame Retardant X2 Second Flame Retardant Y Penetrating Agent

Claims

1. A carpet in which pile (2) is provided on a base fabric (3), The pile (2) is made of nylon 6 fibers. At least the pile (2) is coated with a flame retardant (X) having a first flame retardant (X1) and a second flame retardant (X2), The first flame retardant (X1) contains guazinine sulfamate, The carpet is characterized in that the second flame retardant (X2) contains a guanidine salt of an alkyl acid phosphate ester.

2. The base fabric (3) is made of polypropylene fibers. The first flame retardant (X1) also includes ammonium sulfate, or a mixture of ammonium sulfate and a phosphorus-nitrogen-based onium salt. The carpet according to claim 1, characterized in that the flame retardant (X) is attached to the pile (2) and the base fabric (3).

3. The carpet according to claim 1 or 2, characterized in that the ratio of the amount of the first flame retardant (X1) to the amount of the second flame retardant (X2) applied is 132:3 to 132:

14.

4. At least the pile (2) also has the penetrating agent (Y) attached to it. The carpet according to claim 1, characterized in that the penetrating agent (Y) contains an acetylene glycol-based penetrating agent.

5. A flame retardant comprising a first flame retardant (X1) and a second flame retardant (X2), The first flame retardant (X1) contains guazinine sulfamate, The second flame retardant (X2) is characterized by containing a guanidine salt of an alkyl acid phosphate ester.

6. The flame retardant according to claim 5, characterized in that the first flame retardant (X1) also contains ammonium sulfate, or a mixture of ammonium sulfate and a phosphorus-nitrogen-based onium salt.

7. The flame retardant according to claim 5 or 6, characterized in that the second flame retardant (X2) is a viscous material at room temperature.

8. A method for manufacturing a carpet in which pile (2) is provided on a base fabric (3), The pile (2) is made of nylon 6 fibers, At least the pile (2) is coated with a flame retardant (X) having a first flame retardant (X1) and a second flame retardant (X2), The first flame retardant (X1) contains guazinine sulfamate, A method for producing a carpet, characterized in that the second flame retardant (X2) contains a guanidine salt of an alkyl acid phosphate ester.

9. The method for manufacturing a carpet according to claim 8, characterized in that the second flame retardant (X2) is a viscous material at room temperature.

10. The method for manufacturing a carpet according to claim 8 or 9, characterized in that the flame retardant (X) is applied to at least the pile (2) by spray coating.

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